Operating Instructions Tcbeadmaking Rev02 Alphasensors

Dyna.
WELD THERMOCOUPLE BEAD MAKING MACHINE
USER MANUAL
THERMOCOUPLE BEAD MAKING MACHINE Issue No : I Rev : 02 July 2011 Page No : Page 1 of 11
Address : Hari Nivas, 2
nd
ALPHA SENSORS
Complete Thermometry Solutions
Floor, S.V Road, Khar (W), Mumbai 400 052 Ph : 91-22-28682765 Fax : 91-22-28684428 Email : alphasensors@gmail.com/alphasensors@vsnl.in
MODEL:
Dyna.WELD
Author : Ashish Gupta
PROPRIETARY : This document and data disclosed herein or herewith is not to be reproduced, used or disclosed in whole or in part to anyone without the permission of M/s Precision Sensors Pvt. Ltd., Mumbai
INDEX
SR. NO 1 2 3
TOPIC
WHAT IS CAPACITANCE WELDING INTRODUCTION OF Dyna.WELD and SPECIFICATION PART DIAGRAM & ACCESORY LIST
PAGE 3 3 4 5 5 7 8 9 10 11
4 INSTALLATION & SETUP 5 OPERATIONS & CONTROLS 6 MAINTENANCE 7 SAFETY &TIPS 8. RESISTANCE WELDING 9. WARRANTY CERTIFICATE 10. ENERGY NOTING SHEET
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
OPERATING INSTRUCTIONS
1.0 WHAT IS CAPACITANCE WELDING? In an electrical charge a preset energy level is stored .This charge is then released across two electrodes the negative electrode being the work piece. This discharge of stored energy is sufficient to form the weld. Capacitance welding is generally used for the welding of similar and dissimilar wires (thermocouple junction welds) and for impact welding wires to a conductive material. 2.0 INTRODUCTION OF Dyna.WELD The DYNAWELD is a versatile welder capable of the rapid production of reliable commercial and reference Thermocouple junctions and of connecting extension leads to MI Thermocouples, Resistance Thermometer Detectors and other transducers. It may also be used to attach Thermocouple and other wires to solid metal surfaces, such as pipes, boiler plates, engine blocks, power semiconductors and printed circuit tracks. No special skills are required for its successful operation and most people will be capable of producing quality work after only a few minutes practice.
2.1 SPECIFICATIONS :
A) TECHNICAL
Welding System Energy Range Welding Capacity Supply Voltage Power Consumption Fuse Duty Cycle Dimensions Weight Capacitive Discharge. 4 to 80 Joules. 0.1 to 1.2mm dia. wires 36 to 20 SWG. 220 / 240 VAC 45 / 65 hz. 170 VA maximum. 2 amp / 250 V, 20mm glass. Continuous. 215W x 87H x 195D (mm). Approx. 6 kgs
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
PARTS :
2.2 ACCESSORIES LIST Sr,No 1. 2. 3. 4. 5. 6. 7. 8. 9 Description Dyna.WELDER Main Module Footswitch IEC Mains Cable Spare Electrodes Welding Pliers Magnifying Glass User Manual Allen Key Operation Manual Video CD Quantity 1 nos. 1 nos. 1 nos. 5 nos. 1 nos. 1 nos. 1 nos. 1 nos. 1 nos.
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
3.0 INSTALLATION AND SETUP. 3.1 MAINS CONNECTION. The Mains lead supply is connected to the IEC socket at the rear of the Dyna.WELD 80J and should then be connected to a standard 230V/50HZ supply unless otherwise stated. 3.2 FOOTSWITCH CONNECTION Plug the supplied footswitch connector into the appropriate socket indicated on the front panel of Dyna.WELD 80J. 3.3 WIRE HOLDING PLIERS CONNECTION Plug the wire holding pliers into one of the Positive (+ve) Electrodes(X1,X2 OR X3) marked on the front panel based on the wire diameter to be welded.. 3.4 OPTIONAL IMPACT WELDING SOCKET : A separate -ve socket is provided for impact welding or thermocouple attachment function explained later in the manual. 4.0 OPERATION AND CONTROLS. 4.1 INITIAL SETTING.
STEP I STEP II
: Switch on the mains Supply with the rocker switch built in on the front panel
: Connect the footswitch in the appropriate socket of the front panel and plug the Wire Holding Pliers in the positive socket(+ve) either in X1, X2 or X3 based on wire diameter . Kindly refer to Energy Setting Table 1 explained in Pt. 4.2 below. 4.2 Energy Setting.
STEP III
: Increase the charge voltage reading by moving the potentiometer knob in the clockwise direction appropriate to the size of wires to be welded. The voltage reading will be displayed on the LED Display. There are 3 different energy banks X1, X2, & X3 in the machine which can be selected by the user based on the wire diameter to be welded. X1 is the low energy bank, X2 is the Mid Level Energy bank and X3 is the high energy bank. There may be more than one combination of Charge voltage and Energy Bank selection which may suit welding for a particular wire diameter. The user may make some trials and arrive at the best combination meeting his application requirements.
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
In the table below are some combinations of Capacitor Bank Selection and Charge Voltage based on trials made by us. This table is for representation purposes only to give the user a idea of operation. We always advise the user to make his own trials and arrive at suitable combinations suiting his application requirement. We have provided format of energy Noting sheet at the back of this manual for recording observations of the user. TABLE 1 Wire Diameter(mm) 0.1 0.3 0.5 0.8 0.9 1.0 Charge Voltage Setting (V) With X1 25 V 28 V With X2 18 V 20 V 27 V With X3 15 V 18 V 25 V 36 V 40 V 45 V
**Note: These are few combinations mentioned. Various other combinations can be made with different banks (X1,X2,X3) and voltage level. The energy combination determines the type of bead formed. Some applications require a round bead for usage of thermocouple in harsh environments and in some cases the application requires a thermocouple bead with minimum mass for fast response. NEW FEATURE !!!! : In this model we have added a further feature of using the energy banks in combination. You can now combine energy of two or more banks and discharge them at one time. This will help you in controlling the bead size formed. For Example : By Shorting Banks X1 and X2 together and connecting the plier to either X1 or X2 you can harness the combined energy stored in capacitors of bank X1 and X2. Similarly you can short X1 and X3 , X2 and X3 OR X1, X2 and X3 . It is recommended that the user analyses various options available and decides on the best combination for the type of weld required. STEP IV : Press the Initiate Charging button on the front panel of the machine. The Charging LED will blink till the charging process is complete. Once the LED stops blinking , it indicates that charging is complete
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
4.3 PREPARING WIRES. STEP V : Insulated wires should have their insulation stripped sufficiently to allow at least 5mm protruding when gripped in the pliers. They should be laid side by side and in contact such that the ends square and level. With smaller diameter wires it will be found advantageous to twist them together before trimming .This also applies when welding stranded wires together or stranded wires to solid wires. 4.4 WELD ACTION. STEP VI : Grip the wires in the holding pliers and bring them near the carbon electrode. Check if the charge voltage is stable or is still increasing value. The wires should be held tightly so that always there is positive contact. Position the wires such that they are approx 0.5mm to 1mm away from the carbon electrode. The Purge/Weld Switch must be on the WELD side. Initiate weld sequence by pressing the footswitch. WELD Sequence will first purge the weld area with argon gas and then within 20 seconds automatically discharge the stored energy to weld the thermocouple wires together. After discharge the system will automatically charge to preset charge voltage level for next weld.
4.5 OPTIONAL WELD ACTION I IMPACT WELD ACTION This is the term used for welding wires to a metal (conductive) surface. This type of application is common when the wires are required to be welded to a chassis or framework for testing or heat treatment application. Connect the surface on which the wires is to be welded to the Impact Welding Socket. Negative (-ve.) socket provided on the front panel of Dyna.WELD 80J using a lead wire with one end terminated in a banana plug and the other end terminated in a alligator clip.The alligator clip should then be attached to the surface close to where the wires need to be attached. The prepared wires are then gripped in the wire holding pliers and then pressed on to the surface to which they are to be attached. The weld action describe above should be then followed and when the footswitch is depressed, the resulting discharge will weld the wires to the surface after which the weld clip can be removed. 4.6 WELD QUALITY. Examine the weld using the magnifying glass supplied. A good weld will produce a strong joint between the wires and usually forms a round bead. A flat bridge between the wires indicates too low setting. A flattened hemisphere indicates that energy setting is too high. THERMOCOUPLE BEAD MAKING MACHINE Issue No : I Rev : 02 July 2011 Page No : Page 7 of 11
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
5.0 MAINTENANCE. Apart from Carbon electrode replacement, the Dyna.WELD 80J contains no user serviceable parts. In the event of failure, please return the welder, carefully packed, to the distributor from which it was purchased who will arrange for the necessary repair. 5.1 Carbon Electrode Replacement. After considerable use, the carbon electrode will need attention. The carbon may be trimmed in a drill or lathe chuck using a metal file to give an included angle of about 300 with the tip approx. 2mm diameter. To remove the carbon electrode slacken the grub screw on the argon shield (Allen key provided)and pull off the shield. Slacken the grub screw on the the electrode holder and withdraw the electrode. When fitting a new or trimmed electrode, insert it loosely until it lines up with the front face of the shield. Tighten the grub screw & replace the argon shield. 6.0 SAFETY AND TIPS. Use of Red Welding Glass filter to protect the eyes from the welding flashes is recommended. A bench lamp positioned over the welder will permit the work and carbon electrode tip to be easily seen. Accidental over setting of the energy level can result in flying particles and it is strongly recommended that welding goggles are used at all times. If the pliers become pitted or soiled, clean the faces by pulling through a piece of folded fine emery paper whilst applying slight pressure to the handles. Keep a note book by the welder and make a record of the setting for each type of job. Noting wire size, materials and energy setting .
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
R E S I S T A N C E W E L D I N G K I T O P TI O N A L A C C E S S O R Y K I T. C O N S I S TI N G O F 1 C O P P E R P L A TE + 1 E LE C T R O D E P E N .
The resistance welding attachments are suitable for welding ribbon conductors of up to about 0.3 mm thick depending on the resistivity of the materials. It cannot be used successfully with low resistance materials such as copper, aluminum, silver and gold.
PROCEDURE
Plug the electrode pen in the IMPACT WELD TERMINAL and Copper plate into the welder terminals X1, X2 OR X3. Position the ribbons to be welded on the plate and apply the pen to the point where the weld is to be made. Push down the electrode pen until you are sure that the two ribbons are in intimate contact ( use less pressure with fine materials ) and then operate the foot Switch . Test the strength of the weld on the first sample by pulling the ribbons apart. If the weld appears weak, increase the energy setting on the welder. If the ribbons are pierced, reduce the energy setting. A good weld will show a slightly discoloured disc on the ribbon that was in contact with the copper plate. The system is capable of producing a number of welds in close proximity in order to increase the strength of the joint. A die pattern of five will be found convenient for the wider ribbons. It can also weld ribbons to solid surfaces such as radiators and engine blocks. In this case the copper plate should be clamped to a point on the device, using a Mole grip or similar, where it will make good electrical contact. Alternatively, if a lot of this type of welding is carried out, it will be found more convenient to make up a special lead fitted with a 4mm plug and a heavy duty crocodile clip - the sort used for car battery jump leads is ideal.
TIP M AINTENANCE
To remove the welding tip for replacement or reshaping, remove the tip from the plastic handle by unscrewing the same. To reshape, grip the copper body and sharpen the tip of the electrode on a grinding wheel. The tip should not be very pointy and should have some relief on the top. Always wear protective eye gear as copper is brittle and is liable to break off if too much side force is applied.
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
WARRANTY CERTIFICATE All equipment sold by Alpha Sensors is warranted by Alpha Sensors for the period of twelve months, which period will commence upon date of shipment or invoicing whichever occurs first, to be free from any defects in material and workmanship disclosed under normal use and service, provided such goods have been properly installed, maintained and operated in accordance with Alpha Sensors specifications for such goods. If Purchaser, within such period, notifies Alpha Sensors in writing of any claimed defect in goods delivered by Alpha Sensors and such goods are found by Alpha Sensors, after appropriate tests and inspection, not to be in conformity with this warranty, Alpha Sensors will at its option and expense either repair the same or provide a replacement for installation at Purchasers expense. With respect to services performed hereunder, Alpha Sensors sole liability for any defect therein shall be to perform again, at Alpha Sensors expense, such services. EXCEPT AS AFORESAID, ALPHA SENSORS MAKES NO WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR ANY OTHER OR FURTHER WARRANTY, EITHER EXPRESS OR IMPLIED OR BY TRADE USAGE, IN CONNECTION WITH THE DESIGN, SALE, INSTALLATION, OR USE OF ANY OF THE GOODS REFERRED TO HEREIN, AND LIABILITY FOR THE WARRANTY MADE HEREIN SHALL IN NO EVENT EXCEED THE COST OF CORRECTING DEFECTS IN THE GOODS SOLD OR, AT ALPHA SENSORS OPTION, OF REPLACING SAME WITH NONDEFECTIVE GOODS. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, THE FOREGOING WARRANTY DOES NOT COVER, AND NO WARRANTY IS MADE WITH RESPECT TO :
A. B. C. D. E. F.
Failures not reported within the warranty period above specified. Failures or damage due to negligence (other than that of Alpha Sensors ), accident, improper installation, improper operation or abnormal conditions of temperature, moisture, dirt or corrosion. Goods which have been tampered with, repaired or altered by anyone other than an authorized representative of Alpha Sensors Goods damaged in shipment or otherwise without fault of Alpha Sensors. Expenses incurred by Purchaser in an attempt to correct or repair any alleged defect, unless approved by Alpha Sensors in writing. Components and other materials purchased by Alpha Sensors from other manufacturers and resold to Purchaser either in the form acquired by Alpha Sensors or in assembly with other components and materials. As an accommodation to Purchaser, Alpha Sensors will, upon request of Purchaser, assign to Purchaser any rights it may have arising out of warranties given by any manufacturer of such components, materials or standard equipment purchased by Alpha Sensors and so resold to purchaser Any goods manufactured by Alpha Sensors in response to Purchasers specifications therefor which go beyond the existing state of the art. Alpha Sensors assumes no liability for any failure of such goods so to meet such specifications. Failure or defects attributable to design or specifications requested by Purchaser. Specifications and dimensions shown in this quotation which are approximate and are subject to minor deviations or tolerances in accordance with industry standards. Such components which by their nature in normal usage of the goods in accordance with Alpha Sensors specifications therefor, have a life expectancy shorter than the warranty period, referred to as consumables,. If original seals on instrument are tampered with then all warranties on the equipment are immediately terminated.
G.
H. I. J.
K.
Any representation or warranty beyond that expressly contained herein, whether made prior to or subsequent to the date hereof, are not authorized by Alpha Sensors and shall have not force or effect and shall not be binding upon Alpha Sensors. Sr. No : ALPHA/2012/TBM/1196 Month of Manufacture : May. 2012
nd
ALPHA SENSORS
Author : Dyna.WELD Ashish Gupta MODEL:
ENERGY NOTING SHEET.

Sr.No. Wire Size Material Charge Voltage Energy Bank Selected. X1, X2 or X3 Remarks
nd
ALPHA SENSORS
Dyna.WELD THERMOCOUPLE BEAD MAKING MACHINE
USER MANUAL
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
INDEX
SR. NO 1 2 3
TOPIC
WHAT IS CAPACITANCE WELDING INTRODUCTION OF Dyna.WELD and SPECIFICATION PART DIAGRAM & ACCESORY LIST
PAGE 3 3 4 5 5 7 8 9 10 11
4 INSTALLATION & SETUP 5 OPERATIONS & CONTROLS 6 MAINTENANCE 7 SAFETY &TIPS 8. RESISTANCE WELDING 9. WARRANTY CERTIFICATE 10. ENERGY NOTING SHEET
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
OPERATING INSTRUCTIONS
1.0 WHAT IS CAPACITANCE WELDING? In an electrical charge a preset energy level is stored .This charge is then released across two electrodes the negative electrode being the work piece. This discharge of stored energy is sufficient to form the weld. Capacitance welding is generally used for the welding of similar and dissimilar wires (thermocouple junction welds) and for impact welding wires to a conductive material. 2.0 INTRODUCTION OF Dyna.WELD The DYNAWELD is a versatile welder capable of the rapid production of reliable commercial and reference Thermocouple junctions and of connecting extension leads to MI Thermocouples, Resistance Thermometer Detectors and other transducers. It may also be used to attach Thermocouple and other wires to solid metal surfaces, such as pipes, boiler plates, engine blocks, power semiconductors and printed circuit tracks. No special skills are required for its successful operation and most people will be capable of producing quality work after only a few minutes practice.
2.1 SPECIFICATIONS :
A) TECHNICAL
Welding System Energy Range Welding Capacity Supply Voltage Power Consumption Fuse Duty Cycle Dimensions Weight Capacitive Discharge. 4 to 80 Joules. 0.1 to 1.2mm dia. wires 36 to 20 SWG. 220 / 240 VAC 45 / 65 hz. 170 VA maximum. 2 amp / 250 V, 20mm glass. Continuous. 215W x 87H x 195D (mm). Approx. 6 kgs
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
PARTS :
2.2 ACCESSORIES LIST Sr,No 1. 2. 3. 4. 5. 6. 7. 8. 9 Description Dyna.WELDER Main Module Footswitch IEC Mains Cable Spare Electrodes Welding Pliers Magnifying Glass User Manual Allen Key Operation Manual Video CD Quantity 1 nos. 1 nos. 1 nos. 5 nos. 1 nos. 1 nos. 1 nos. 1 nos. 1 nos.
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
3.0 INSTALLATION AND SETUP. 3.1 MAINS CONNECTION. The Mains lead supply is connected to the IEC socket at the rear of the Dyna.WELD 80J and should then be connected to a standard 230V/50HZ supply unless otherwise stated. 3.2 FOOTSWITCH CONNECTION Plug the supplied footswitch connector into the appropriate socket indicated on the front panel of Dyna.WELD 80J. 3.3 WIRE HOLDING PLIERS CONNECTION Plug the wire holding pliers into one of the Positive (+ve) Electrodes(X1,X2 OR X3) marked on the front panel based on the wire diameter to be welded.. 3.4 OPTIONAL IMPACT WELDING SOCKET : A separate -ve socket is provided for impact welding or thermocouple attachment function explained later in the manual. 4.0 OPERATION AND CONTROLS. 4.1 INITIAL SETTING.
STEP I STEP II
: Switch on the mains Supply with the rocker switch built in on the front panel
: Connect the footswitch in the appropriate socket of the front panel and plug the Wire Holding Pliers in the positive socket(+ve) either in X1, X2 or X3 based on wire diameter . Kindly refer to Energy Setting Table 1 explained in Pt. 4.2 below. 4.2 Energy Setting.
STEP III
: Increase the charge voltage reading by moving the potentiometer knob in the clockwise direction appropriate to the size of wires to be welded. The voltage reading will be displayed on the LED Display. There are 3 different energy banks X1, X2, & X3 in the machine which can be selected by the user based on the wire diameter to be welded. X1 is the low energy bank, X2 is the Mid Level Energy bank and X3 is the high energy bank. There may be more than one combination of Charge voltage and Energy Bank selection which may suit welding for a particular wire diameter. The user may make some trials and arrive at the best combination meeting his application requirements.
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
In the table below are some combinations of Capacitor Bank Selection and Charge Voltage based on trials made by us. This table is for representation purposes only to give the user a idea of operation. We always advise the user to make his own trials and arrive at suitable combinations suiting his application requirement. We have provided format of energy Noting sheet at the back of this manual for recording observations of the user. TABLE 1 Wire Diameter(mm) 0.1 0.3 0.5 0.8 0.9 1.0 Charge Voltage Setting (V) With X1 25 V 28 V With X2 18 V 20 V 27 V With X3 15 V 18 V 25 V 36 V 40 V 45 V
**Note: These are few combinations mentioned. Various other combinations can be made with different banks (X1,X2,X3) and voltage level. The energy combination determines the type of bead formed. Some applications require a round bead for usage of thermocouple in harsh environments and in some cases the application requires a thermocouple bead with minimum mass for fast response. NEW FEATURE !!!! : In this model we have added a further feature of using the energy banks in combination. You can now combine energy of two or more banks and discharge them at one time. This will help you in controlling the bead size formed. For Example : By Shorting Banks X1 and X2 together and connecting the plier to either X1 or X2 you can harness the combined energy stored in capacitors of bank X1 and X2. Similarly you can short X1 and X3 , X2 and X3 OR X1, X2 and X3 . It is recommended that the user analyses various options available and decides on the best combination for the type of weld required. STEP IV : Press the Initiate Charging button on the front panel of the machine. The Charging LED will blink till the charging process is complete. Once the LED stops blinking , it indicates that charging is complete
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
4.3 PREPARING WIRES. STEP V : Insulated wires should have their insulation stripped sufficiently to allow at least 5mm protruding when gripped in the pliers. They should be laid side by side and in contact such that the ends square and level. With smaller diameter wires it will be found advantageous to twist them together before trimming .This also applies when welding stranded wires together or stranded wires to solid wires. 4.4 WELD ACTION. STEP VI : Grip the wires in the holding pliers and bring them near the carbon electrode. Check if the charge voltage is stable or is still increasing value. The wires should be held tightly so that always there is positive contact. Position the wires such that they are approx 0.5mm to 1mm away from the carbon electrode. The Purge/Weld Switch must be on the WELD side. Initiate weld sequence by pressing the footswitch. WELD Sequence will first purge the weld area with argon gas and then within 20 seconds automatically discharge the stored energy to weld the thermocouple wires together. After discharge the system will automatically charge to preset charge voltage level for next weld.
4.5 OPTIONAL WELD ACTION I IMPACT WELD ACTION This is the term used for welding wires to a metal (conductive) surface. This type of application is common when the wires are required to be welded to a chassis or framework for testing or heat treatment application. Connect the surface on which the wires is to be welded to the Impact Welding Socket. Negative (-ve.) socket provided on the front panel of Dyna.WELD 80J using a lead wire with one end terminated in a banana plug and the other end terminated in a alligator clip.The alligator clip should then be attached to the surface close to where the wires need to be attached. The prepared wires are then gripped in the wire holding pliers and then pressed on to the surface to which they are to be attached. The weld action describe above should be then followed and when the footswitch is depressed, the resulting discharge will weld the wires to the surface after which the weld clip can be removed. 4.6 WELD QUALITY. Examine the weld using the magnifying glass supplied. A good weld will produce a strong joint between the wires and usually forms a round bead. A flat bridge between the wires indicates too low setting. A flattened hemisphere indicates that energy setting is too high. THERMOCOUPLE BEAD MAKING MACHINE Issue No : I Rev : 02 July 2011 Page No : Page 7 of 11
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
5.0 MAINTENANCE. Apart from Carbon electrode replacement, the Dyna.WELD 80J contains no user serviceable parts. In the event of failure, please return the welder, carefully packed, to the distributor from which it was purchased who will arrange for the necessary repair. 5.1 Carbon Electrode Replacement. After considerable use, the carbon electrode will need attention. The carbon may be trimmed in a drill or lathe chuck using a metal file to give an included angle of about 300 with the tip approx. 2mm diameter. To remove the carbon electrode slacken the grub screw on the argon shield (Allen key provided)and pull off the shield. Slacken the grub screw on the the electrode holder and withdraw the electrode. When fitting a new or trimmed electrode, insert it loosely until it lines up with the front face of the shield. Tighten the grub screw & replace the argon shield. 6.0 SAFETY AND TIPS. Use of Red Welding Glass filter to protect the eyes from the welding flashes is recommended. A bench lamp positioned over the welder will permit the work and carbon electrode tip to be easily seen. Accidental over setting of the energy level can result in flying particles and it is strongly recommended that welding goggles are used at all times. If the pliers become pitted or soiled, clean the faces by pulling through a piece of folded fine emery paper whilst applying slight pressure to the handles. Keep a note book by the welder and make a record of the setting for each type of job. Noting wire size, materials and energy setting .
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
R E S I S T A N C E W E L D I N G K I T O P TI O N A L A C C E S S O R Y K I T. C O N S I S TI N G O F 1 C O P P E R P L A TE + 1 E LE C T R O D E P E N .
The resistance welding attachments are suitable for welding ribbon conductors of up to about 0.3 mm thick depending on the resistivity of the materials. It cannot be used successfully with low resistance materials such as copper, aluminum, silver and gold.
PROCEDURE
Plug the electrode pen in the IMPACT WELD TERMINAL and Copper plate into the welder terminals X1, X2 OR X3. Position the ribbons to be welded on the plate and apply the pen to the point where the weld is to be made. Push down the electrode pen until you are sure that the two ribbons are in intimate contact ( use less pressure with fine materials ) and then operate the foot Switch . Test the strength of the weld on the first sample by pulling the ribbons apart. If the weld appears weak, increase the energy setting on the welder. If the ribbons are pierced, reduce the energy setting. A good weld will show a slightly discoloured disc on the ribbon that was in contact with the copper plate. The system is capable of producing a number of welds in close proximity in order to increase the strength of the joint. A die pattern of five will be found convenient for the wider ribbons. It can also weld ribbons to solid surfaces such as radiators and engine blocks. In this case the copper plate should be clamped to a point on the device, using a Mole grip or similar, where it will make good electrical contact. Alternatively, if a lot of this type of welding is carried out, it will be found more convenient to make up a special lead fitted with a 4mm plug and a heavy duty crocodile clip - the sort used for car battery jump leads is ideal.
TIP M AINTENANCE
To remove the welding tip for replacement or reshaping, remove the tip from the plastic handle by unscrewing the same. To reshape, grip the copper body and sharpen the tip of the electrode on a grinding wheel. The tip should not be very pointy and should have some relief on the top. Always wear protective eye gear as copper is brittle and is liable to break off if too much side force is applied.
nd
ALPHA SENSORS
MODEL:
Dyna.WELD
WARRANTY CERTIFICATE All equipment sold by Alpha Sensors is warranted by Alpha Sensors for the period of twelve months, which period will commence upon date of shipment or invoicing whichever occurs first, to be free from any defects in material and workmanship disclosed under normal use and service, provided such goods have been properly installed, maintained and operated in accordance with Alpha Sensors specifications for such goods. If Purchaser, within such period, notifies Alpha Sensors in writing of any claimed defect in goods delivered by Alpha Sensors and such goods are found by Alpha Sensors, after appropriate tests and inspection, not to be in conformity with this warranty, Alpha Sensors will at its option and expense either repair the same or provide a replacement for installation at Purchasers expense. With respect to services performed hereunder, Alpha Sensors sole liability for any defect therein shall be to perform again, at Alpha Sensors expense, such services. EXCEPT AS AFORESAID, ALPHA SENSORS MAKES NO WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR ANY OTHER OR FURTHER WARRANTY, EITHER EXPRESS OR IMPLIED OR BY TRADE USAGE, IN CONNECTION WITH THE DESIGN, SALE, INSTALLATION, OR USE OF ANY OF THE GOODS REFERRED TO HEREIN, AND LIABILITY FOR THE WARRANTY MADE HEREIN SHALL IN NO EVENT EXCEED THE COST OF CORRECTING DEFECTS IN THE GOODS SOLD OR, AT ALPHA SENSORS OPTION, OF REPLACING SAME WITH NONDEFECTIVE GOODS. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, THE FOREGOING WARRANTY DOES NOT COVER, AND NO WARRANTY IS MADE WITH RESPECT TO :
A. B. C. D. E. F.
Failures not reported within the warranty period above specified. Failures or damage due to negligence (other than that of Alpha Sensors ), accident, improper installation, improper operation or abnormal conditions of temperature, moisture, dirt or corrosion. Goods which have been tampered with, repaired or altered by anyone other than an authorized representative of Alpha Sensors Goods damaged in shipment or otherwise without fault of Alpha Sensors. Expenses incurred by Purchaser in an attempt to correct or repair any alleged defect, unless approved by Alpha Sensors in writing. Components and other materials purchased by Alpha Sensors from other manufacturers and resold to Purchaser either in the form acquired by Alpha Sensors or in assembly with other components and materials. As an accommodation to Purchaser, Alpha Sensors will, upon request of Purchaser, assign to Purchaser any rights it may have arising out of warranties given by any manufacturer of such components, materials or standard equipment purchased by Alpha Sensors and so resold to purchaser Any goods manufactured by Alpha Sensors in response to Purchasers specifications therefor which go beyond the existing state of the art. Alpha Sensors assumes no liability for any failure of such goods so to meet such specifications. Failure or defects attributable to design or specifications requested by Purchaser. Specifications and dimensions shown in this quotation which are approximate and are subject to minor deviations or tolerances in accordance with industry standards. Such components which by their nature in normal usage of the goods in accordance with Alpha Sensors specifications therefor, have a life expectancy shorter than the warranty period, referred to as consumables,. If original seals on instrument are tampered with then all warranties on the equipment are immediately terminated.
G.
H. I. J.
K.
Any representation or warranty beyond that expressly contained herein, whether made prior to or subsequent to the date hereof, are not authorized by Alpha Sensors and shall have not force or effect and shall not be binding upon Alpha Sensors. Sr. No : ALPHA/2012/TBM/1196 Month of Manufacture : May. 2012
nd
ALPHA SENSORS
ENERGY NOTING SHEET.

Sr.No. Wire Size Material Charge Voltage Energy Bank Selected. X1, X2 or X3 Remarks
nd
ALPHA SENSORS

Operating Instructions Tcbeadmaking Rev02 Alphasensors

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Operating Instructions Tcbeadmaking Rev02 Alphasensors

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Dyna.

WELD THERMOCOUPLE BEAD MAKING MACHINE

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Dyna.WELD Ashish Gupta MODEL:

ENERGY NOTING SHEET.

Author : Dyna.WELD Ashish Gupta MODEL:

Dyna.WELD THERMOCOUPLE BEAD MAKING MACHINE

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Ashish Gupta

Author : Dyna.WELD Ashish Gupta MODEL:

ENERGY NOTING SHEET.

Author : Dyna.WELD Ashish Gupta MODEL:

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